Method of manufacturing, packing and transporting computers

ABSTRACT

A method of manufacturing, packing, and transporting a plurality of computers, including the steps of assembling a plurality of computers, providing a rack adapted to support the computers, and positioning the computers onto the rack. The method continues by loading the rack onto a transport vehicle at a first location (e.g., at the manufacturing facility), moving the loaded transport vehicle to a second location (e.g., at the buyer&#39;s facility), unloading the rack from the transport vehicle, and removing the computers from the rack. The providing step can include the step of placing a shock-absorbing pad on the rack, and the positioning step can comprise positioning the computers onto the shock-absorbing pad. In addition, a shock-absorbing pad can be positioned above and on the sides of the plurality of computers. In one embodiment, the rack includes rollers, in which case the loading step includes rolling the rack onto the transport vehicle, and the unloading step includes rolling the rack off of the transport vehicle.

RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 09/072,845filed on May 5, 1998 and issued as U.S. Pat. No. 6,135,706 on Oct. 24,2000, the entire disclosure of which is incorporated herein byreference.

FIELD OF THE INVENTION

The present invention generally relates to the field of computers, andspecifically to the field of manufacturing, packing, and transportingpersonal computers.

BACKGROUND OF THE INVENTION

Because of their fragile nature, personal computers must be handled withextreme care during packing and transporting operations. Typically,computers are packaged at the manufacturing facility using cardboardboxes and resilient inserts. For example, large foam blocks can bepositioned over the ends of the computer, and the resulting assembly canthen be inserted into a heavy-duty cardboard box. The box issubsequently sealed closed by taping or gluing.

To provide adequate protection from the shocks that can be incurredduring the transporting process, it is well-known that the foam blocksmust be relatively thick. Typically, the foam is roughly half thethickness of the computer on all sides of the computer. In addition, inorder to allow the packaged computers to be stacked, the cardboard boxmust be very strong. Due to the size of the computers and the thicknessof the foam, these boxes must also be very large. It is estimated thatthe foam and cardboard associated with packaging computers costs roughly$12 per computer.

During transport, the computers are commonly stacked onto a pallet andsecured in place using packing straps, stretch wrap, or both. Whenstacked in this configuration, roughly eighteen (18) computers can bestacked onto a pallet. The packaged and palleted computers occupyroughly eighty-six (86) cubic feet.

When the packaged computer is received by the user, the box is cut open,typically using a knife or other sharp tool. The computer and foam arethen carefully removed from the box, and the foam blocks are removedfrom the end of the computer. The user must then dispose of thecardboard and foam, which is undesirable from an environmentalperspective. If a large quantity of computers are being received, thetasks of opening the boxes, removing the computers, and disposing thepackaging materials can be significant, and can result in considerableexpense to the user.

SUMMARY OF THE INVENTION

The present invention provides a method of manufacturing, packing, andtransporting computers that does not require the above-described thickfoam blocks and heavy-duty cardboard, thereby saving considerableup-front cost in packing computers. In addition, the present inventionfacilitates transporting computers in a more compact arrangement,thereby reducing transportation costs. The present invention also avoidsthe need to open boxes and remove the computers from boxes, therebysaving the user time when receiving the computers. The present inventionalso does not utilize disposable foam and/or cardboard, and thereforesaves the time and money associated with disposal of these items and ismore environmentally sound.

More specifically, instead of using individual cardboard boxes, thickfoam blocks, and pallets, the present invention utilizes a rack thatsafely holds a plurality of computers. The rack includes at least onesupport member dimensioned to support a plurality of computers. At leastone shock-absorbing pad (e.g., anti-static polyethylene) is supported bythe support member, and the computers are supported by theshock-absorbing pad(s). The rack can be provided with rollers mounted toa bottom portion of the rack to facilitate movement of the assembly ontoand off of a transport vehicle.

The shock-absorbing pad can include a lower portion positioned under atleast one of the computers, and/or a side portion positioned along aside of at least one of the computers. Preferably, at least one of thepads includes a unitary lower portion that supports more than onecomputer (e.g., in inverted T-shaped pad). The pad can be secured to thesupport member in such a manner that it can be selectively detached fromthe support member (e.g., using a hook and loop fastener). The assemblycan also include at least one upper shock-absorbing pad positioned abovethe computers. Preferably, the upper shock-absorbing pad comprises anupper portion positioned above at least one of the computers and a sideportion positioned along a side of at least one of the computers.

The above-described rack can be utilized to practice an innovativemethod of manufacturing, packing, and transporting a plurality ofcomputers. The method includes the steps of assembling a plurality ofcomputers, providing a rack adapted to support the computers, andpositioning the computers onto the rack. The method continues by loadingthe rack onto a transport vehicle at a first location (e.g., at themanufacturing facility), moving the loaded transport vehicle to a secondlocation (e.g., at the buyer's facility), unloading the rack from thetransport vehicle, and removing the computers from the rack.

Preferably, the providing step includes the step of placing ashock-absorbing pad on the rack, and the positioning step comprisespositioning the computers onto the shock-absorbing pad. In addition, ashock-absorbing pad can be positioned above and on the sides of theplurality of computers. In one embodiment, the rack includes rollers, inwhich case the loading step includes rolling the rack onto the transportvehicle, and the unloading step includes rolling the rack off of thetransport vehicle. In order to reduce contamination of the computers,the method can further include the step of wrapping the rack with abarrier material (e.g., stretch wrap).

If desired, some of the concepts of the present invention can beutilized to perform a method of distributing new or refurbishedcomputers within a facility. For example, the buyer of computers canreceive the computers (e.g., in boxes or otherwise) and place them on amobile rack. The rack can then be moved from a first location within thebuyer's facility to a second location where a computer is removed fromthe rack (e.g., at the location where the computer will be operated). Ifthe computer is replacing an old computer, then the old computer can beplaced onto the rack (e.g., in the location where the new or refurbishedcomputer was located). The rack can then be moved to additionallocations for delivery and/or pickup of additional computers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a rack assembly holding a plurality ofcomputers and covered with stretch wrap.

FIG. 2 is a perspective view of the rack of FIG. 1 with the stretch wrapand one of the upper supports removed.

FIG. 3 is an enlarged perspective view of the rack of FIG. 2 with one ofthe computers removed.

FIG. 4 is an enlarged front view of the rack in FIG. 1 with the stretchwrap removed.

FIG. 5 is a section view taken along line 5—5 in FIG. 4.

FIG. 6 is a perspective view of the interior of a transport vehicle withthe rack and computer assembly of FIG. 1 secured in place.

FIG. 7 is a partial perspective view of an alternative embodiment of thepresent invention.

FIG. 8 is a perspective view of a rack according to the presentinvention, shown with computers being programmed on the rack.

DETAILED DESCRIPTION

FIGS. 1-3 illustrate a rack and computer assembly embodying the presentinvention. The illustrated assembly 10 includes a rack 12 havingvertical members 14 supporting a series of support members 16 verticallyspaced with respect to each other. Each support member 16 is dimensionedto support one or more computers 18. As used herein, the term computerrefers to the portion of a personal computer that contains thecomputer's microprocessor. Each computer 18 includes a top 20, a bottom22, and four sides 24.

Each support member 16 includes one or more shock-absorbing pads. In theillustrated embodiment, each support member 16 includes four lower pads26 positioned to support three computers 18 in spaced relation relativeto the corresponding support member 16. More specifically, each lowerpad 26 includes a lower portion 28 positioned under at least onecomputer 18 and a side portion 30 positioned along a side of at leastone computer 18. As can be seen in FIG. 1, the two lower pads 26 on theends of each support member 16 are L-shaped to support one end of acomputer 18, and the two lower pads 26 toward the middle of each supportmember 16 are an inverted T-shape to support the sides of two differentcomputers 18.

Each of the lower pads 26 is detachably secured to a correspondingsupport member 16. In the illustrated embodiment, a selectivelydetachable fastener is used to detachably secure each lower pad 26 tothe corresponding support member 16. As used herein, the termselectively detachable means that it can be detached without the needfor tools. For example, referring to FIGS. 4 and 5, a hook and loopfastener 32 could be utilized with the hook portion secured to the lowerpad 26 and the loop portion secured to the support member 16. By makingthe lower pads 26 detachable, the lower pads 26 can be repositionedrelative to the support members 16 to accommodate computers of differentsizes and to facilitate quick replacement of the lower pads 26.

Referring to FIG. 2, the assembly 10 further includes an upper pad 34positioned above the computers 18. Each upper pad 34 includes an upperportion 36 positioned above the top of the computers 18 and a sideportion 38 positioned along a side of the computers 18. In theillustrated embodiment, each upper portion 36 spans the width of threecomputers 18 and includes three individual side portions 38 forsupporting the sides of each corresponding computer 18. Although notexplicitly shown in FIG. 2, the opposing side of each computer 18 isalso supported by an upper pad 34.

The upper pads 34 are also detachable from the support members 16. Inthe illustrated embodiment, the upper pads 34 are provided with straps40 that can be secured to the rack 12. For example, referring to FIGS. 4and 5, each strap 40 can be provided with a hook and loop fastener 42 toallow the strap 40 to be wrapped around a support member 16 and securedback onto itself. It should be appreciated that the use of detachablefasteners for the pads is not necessary to practice the presentinvention. In fact, it has been found that, due to the configuration ofthe support members 16 (described below in more detail), the upper pads34 stay in place without the need for the straps 40. However, the straps40 are helpful in keeping the upper pads 34 in place on the rack 12 whennot being used to support a computer 18 (e.g., when an empty rack isbeing transported).

Referring to FIGS. 4 and 5, each support member 16 of the illustratedembodiment is of a metal wire frame design. The wire frame designfacilitates wrapping the straps 40 of the upper pad 34 between the wiremembers 44 to secure the upper pad 34 to the rack 12. Each supportmember 16 further includes front and rear lip portions 46 that extenddownwardly from the front and rear of each support member 16. The lipportions 46 provide strength and rigidity to the support members 16. Inaddition, the lip portions 46 assist in maintaining the upper pads 34 inposition.

The shock-absorbing pads of the present invention can comprise anysuitable material. For example, in the illustrated embodiment, theshock-absorbing pads comprise anti-static polyethylene. However, it isalso within the scope of the present invention to use alternativeshock-absorbing materials such as foam rubber, polymer elastomers,springs, or any other suitable material.

Each rack 12 is also provided with rollers 48 secured to a bottomportion of the rack. The rollers 48 facilitate moving the rack 12 ontoand off of a transport vehicle 50. In addition, the rollers 12facilitate using the rack 12 for delivering the computers 18 to theappropriate work stations upon arrival at the user's facility. Therollers 48 can comprise a typical caster, and preferably also includelocking devices (not shown) that can be actuated by the user to inhibitthe rack from moving during transport.

In order to prevent the assembly 10 from tipping during transport, thetransport vehicle 50 can be provided with a securing device. Referringto FIG. 6, the illustrated securing device includes a load bar 52 thatspans the width of the transport vehicle 50. The load bar 52 ispositioned approximately at the mid-point of the assembly 10. The loadbar 52 sandwiches the assembly 10 against the wall 54 of the transportvehicle 50, against another rack, or against another load bar. Insteadof a load bar 52, the securing device could instead comprise straps (notshown) secured to the wall and wrapped around the rack, a clampingmechanism secured to the wall and clamped to the rack, or any othersuitable device. In this manner, the rack 12 is prevented from tippingin the transport vehicle 50 during transportation operations.

The above-described computer and rack assembly 10 is wrapped in abarrier material. The illustrated barrier material comprises atransparent stretch wrap material (FIG. 1) that is commonly used to wrapboxed and palleted computers. The barrier material is utilized toinhibit contamination of the computers during transport.

FIG. 7 illustrates an alternative embodiment of the present invention.In the alternate embodiment, the lower pads 60 extend the length of therack 62, and the upper pads 64 extend the width of the rack 62.

The above-described rack assembly can be used to practice a method ofmanufacturing, packing and transporting computers in accordance with thepresent invention. The method includes the step of assembling aplurality of computers 18. The assembly of computers involves assemblingindividual computer components (e.g., motherboards, chips, hard drives,etc.) into a computer shell. Assembly of computers is well-known in thisfield, and should require no further description. The method furtherincludes the steps of providing the rack 12, positioning the computers18 onto the rack 12, and loading the rack 12 onto a transport vehicle 50at a first location. The transport vehicle 50 can then be moved to asecond location where the rack 12 is unloaded from the transport vehicle50 and the computers 18 are removed from the rack 12.

It should be appreciated that the method can also include adding theshock-absorbing pads to the rack to protect the computers from beingdamaged during transport. Positioning the pads below, above, and on thesides of the computers is preferred. In addition, the rack can beprovided with rollers 48 to facilitate rolling the rack 12 onto thetransport vehicle 50 and off of the transport vehicle 50. In a preferredembodiment, the method further includes the step of locking the rollers48 and securing the racks 12 in the transport vehicle using theabove-described securing device.

By utilizing the above-described rack assembly, it has been found thatthe total shipping volume of the computers has been significantlyreduced. More specifically, the total shipping volume of eighteencomputers on the above-described rack is about fifty-seven (57) cubicfeet, compared to about eighty-six (86) cubic feet for the same eighteencomputers that are packaged in the typical foam and boxes and stackedonto a pallet. This results in a reduction of about thirty-four percent(34%) on the shipping volume. In addition, because the rack is rolledonto the transport vehicle as opposed to lifted by a forklift, it isbelieved that the potential for damage to the computers is significantlyreduced.

The rack can also be used to distribute new or refurbished computerswithin a facility (e.g., the buyer's facility). More specifically, therack can be moved from a first location within a facility to a secondlocation within the facility. At the second location, a computer can beremoved from the rack, preferably at the location where the computerwill be operated. If the computer is replacing an old computer, the oldcomputer can be placed on the rack, where the new computer was located,and subsequently transported to a desired location (e.g., forrefurbishing, disposing, or transporting to a different facility). Itshould be appreciated that this method can be performed even if thecomputers do not arrive at the buyers facility on the racks. That is,the buyer can receive the computers in any form (e.g., in boxes) andplace them on the racks.

The above-described methods are preferably both performed so that thecomputers are placed on racks at the manufacturing facility, transportedon racks, and delivered to the desired locations within the buyer'sfacility using racks. In a preferred method, the buyer maintains one ormore racks on site so that old computers can be placed onto the racks.When a shipment of new computers arrives (i.e., on racks) from themanufacturer, the racks of new computers are removed from the transportvehicle, and the racks of old computers are loaded onto the vehicle. Theold computers can be returned to the manufacturer for salvaging orrefurbishing. Utilizing this method, it can be appreciated that thebuyer will always have one or more racks on site so that the receipt anddelivery of computers can be performed in an efficient manner.

In some instances, the buyer will want to customize the computers insome fashion. For example, the buyer may want to download software,network information, or other information onto the computers that thebuyer receives from the manufacturer. This process is made moreefficient by the use of the above-described racking system and byproviding a master programming computer with multiple connections. In apreferred embodiment, the racks hold eighteen computers, and the masterprogramming computer includes eighteen independent connectors that canbe connected to the eighteen computers on the rack simultaneously themaster programming computer can then be used to selectively program theeighteen computers on the rack.

The foregoing description of the present invention has been presentedfor purposes of illustration and description. Furthermore, thedescription is not intended to limit the invention to the form disclosedherein. Consequently, variations and modifications commensurate with theabove teachings, and the skill or knowledge of the relevant art, arewithin the scope of the present invention. The embodiments describedherein are further intended to explain best modes known for practicingthe invention and to enable others skilled in the art to utilize theinvention in such, or other, embodiments and with various modificationsrequired by the particular applications or uses of the presentinvention. It is intended that the appended claims be construed toinclude alternative embodiments to the extent permitted by the priorart.

What is claimed is:
 1. A method of reducing computer packaging anddistribution costs in the assembly and transport of new computers, themethod comprising: assembling a plurality of new computers at amanufacturing facility; placing the plurality of new computersunpackaged upon a rack at the manufacturing facility; positioning theplurality of computers in a compact arrangement on the rack enabled bythe lack of packaging around the computers; loading the rack with theplurality of computers upon a vehicle; moving the vehicle from themanufacturing facility to a facility of a second party; unloading therack with the plurality of computers from the vehicle; transporting therack to a desired location in the second party's facility; removing theunpackaged computers from the rack; and the second party receiving theunpackaged computers.
 2. The method as claimed in claim 1, furthercomprising: transporting the rack back to the vehicle at the secondparty's facility; loading the rack back upon the vehicle; moving thevehicle back to the manufacturing facility; unloading the rack from thevehicle at the manufacturing facility; and repeating all steps at leastonce.
 3. The method as claimed in claim 1, further comprising: placingat least one old computer unpackaged upon the rack at the second party'sfacility; transporting the rack back to the vehicle; loading the rackback upon the vehicle; and moving the vehicle with the rack away fromsecond party's facility.
 4. The method as claimed in claim 1, furthercomprising: connecting the plurality of new computers on the rack to amaster computer; and programming the plurality of new computers on therack by the master computer.
 5. The method as claimed in claim 1,further comprising reducing the exposure of the plurality of newunpackaged computers on the rack to shock and vibration during theplacing, positioning, loading, moving, unloading, transporting, andremoving steps.
 6. A method of manufacturing and distributing computersto customers, comprising: assembling a plurality of computers at acomputer manufacturing facility; placing the plurality of computers upona rack adapted to support the plurality of computers; loading the rackwith the plurality of computers upon a vehicle; moving the vehicle fromthe computer manufacturing facility to a facility of a customer;unloading the rack with the plurality of computers from the vehicle;moving the rack with the plurality of computers to a first location inthe customer's facility; removing at least one of the computers from therack; delivering the at least one of the computers to the customer;moving the rack to a second location in the customer's facility;removing at least one other computer from the rack; and delivering theat least one other computer to the customer.
 7. The method as claimed inclaim 6, further comprising: placing at least one other computer uponthe rack at the customer's facility; loading the rack upon the vehicle;and transporting the vehicle with the rack from the customer's facility.8. The method as claimed in claim 6, further comprising: repeating thesecond step of moving the rack and the step of delivering at least oneother computer as many times as desired.
 9. The method as claimed inclaim 6, further comprising: leaving the rack at the customer'sfacility; loading a second rack at the customer's facility upon thevehicle; moving the vehicle back to the manufacturing facility;unloading the rack from the vehicle at the manufacturing facility; andrepeating the assembling, placing, first loading, first moving, firstunloading, first removing, and first delivering steps with the secondrack.
 10. The method as claimed in claim 6, further comprising:releasably securing the rack within the vehicle prior to moving thevehicle; and releasing the rack from within the vehicle after moving thevehicle.
 11. The method as claimed in claim 6, further comprising:connecting the plurality of computers on the rack to a master computer;and programming the plurality of computers on the rack by the mastercomputer.
 12. The method as claimed in claim 6, further comprising:loading the rack back upon the vehicle; moving the vehicle from thecustomer's facility back to the manufacturing facility; unloading therack from the vehicle at the manufacturing facility; and repeating allassembling, placing, loading, moving, unloading, removing, anddelivering steps at least once again.
 13. The method as claimed in claim6, further comprising reducing exposure of the plurality of computers toshock and vibration during the placing, loading, moving, unloading, andremoving steps.
 14. A method of performing a transaction in whichcomputers are supplied by a computer supplier to a second party, themethod comprising: the computer supplier placing a plurality ofunpackaged computers upon a rack at a facility of the computer supplier;loading the rack with the plurality of unpackaged computers upon avehicle at the computer supplier's facility; moving the vehicle to afacility of the second party; unloading the rack from the vehicle at thesecond party's facility; transporting the rack from the vehicle toanother location in the second party's facility; removing at least oneof the plurality of unpackaged computers from the rack; the second partyreceiving the at least one of the plurality of unpackaged computers;receiving another unpackaged computer from the second party; placing theother unpackaged computer upon the rack at the second party's facility;transporting the rack from the other location in the second party'sfacility back to the vehicle; loading the rack upon the vehicle at thesecond party's facility; and returning the vehicle to the computersupplier's facility.
 15. The method as claimed in claim 14 furthercomprising: securing the rack in the vehicle prior to moving thevehicle; and unsecuring the rack after moving the vehicle.
 16. Themethod as claimed in claim 14, further comprising: connecting theplurality of unpackaged computers on the rack to a master computer; andprogramming the plurality of unpackaged computers on the rack by themaster computer.
 17. The method as claimed in claim 14, furthercomprising: unloading the rack at the computer supplier's facility; andrepeating all steps to define a systematic manner of performing computersupplying transactions between the computer supplier and second parties.18. The method as claimed in claim 14, further comprising: transportinga second rack to the vehicle at the second party's facility; loading thesecond rack upon the vehicle at the second party's facility; moving thevehicle back to the computer supplier's facility; and unloading thesecond rack from the vehicle at the computer supplier's facility. 19.The method as claimed in claim 14, further comprising reducing exposureof the plurality of unpackaged computers to shock and vibration duringthe placing, loading, moving, unloading, transporting, and removingsteps.